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In a couple of weeks I'll be travelling by air on 2 separate airlines with insulin for my dog that must be kept refrigerated else it spoils, and I have no idea how to go about this. I'll probably be travelling with a handful of vials as he'll need a supply before I can get a new prescription for him from a local vet upon arrival.

It's delivered to me using those freezer packs, but as they're a gel they won't get through security (I assume). I can't think of any other way to transport this on my person. Can anyone offer some guidance as to how I can keep it cold throughout my travels?

I'll be travelling from Manchester Airport (MAN) with Thomas Cook Airlines, and from JFK with American Airlines, if it helps.

Contact the airlines in question. You're not the first person with such needs, and they will have special procedures in place. Most likely it'll be something like you hand over the goods to them and they make sure it gets packaged and transported for you and then handed over to you on arrival.

As the medication is for a pet, the airlines' animal handling departments are probably the most appropriate people for you to approach.

While meant for humans, the American Diabetes Association says that restrictions on liquids and gels don't apply towards insulin and related products. Maybe contacting them can also give you some more information: ADA website

According to USA Today (again, for humans):

Insulin pumps, syringes, ice packs and other equipment related to diabetes management are also exempt from the rule, provided the traveler is also carrying the insulin itself. TSA agents should also allow passengers with diabetes to carry juice or any other medically-necessary liquids through security, even in quantities exceeding 3.4 ounces.

I'm someone who has to travel with refrigerated medication too, and have done so to the USA from the UK a couple of times in the last five years. While just my experience, I've never had any issues. My procedure is:

1) the medication and ice packs go in a separate (offical looking) bag, with the sharps bin and a note from my doctor. If the medicine has any notes saying it must be refrigerated, I add one of them too

2) when I show up at the scanner, I tell them I have a bag with medicine and ice packs in it, and that there is a doctor's note in the top.

3) Generally, they swab the inside with one of the explosive detector things, and wave me through

The customs officers are seriously used to it, there's a good procedure in place. I think it's important to be a bit proactive about telling people, and they seem to appreciate if you let them know before it goes through the scanner. Every now and then they have to go look for a manager, but it's always been fine after that.

I highly recommend a FRIO cooling case. They are designed for this exact purpose and do not require liquids or gels to function. You have to soak the case in water for it to work, but this can be done once you are past security. This will also allow you to keep the medication on you instead of handing it over for transport.

I've personally used it to bring insulin on dozens of flights and I've never had an issue.

"Dry Ice" (solid CO2) is/was allowed to be carried in carryon luggage for food cooling use [!!!].

Do check latest rules.

This is actually a dangerous allowance but did exist a few years back (long after "9/11" when I traveled a lot.

If Dry Ice is wrapped in enough insulation it can last for days.

It self cools the remainder as it "sublimes" to gas - no liquid is produced.

I've managed to keep a small portion of some dry ice solid for up to a week by using more insulation than you wish to carry. (In a medium size domestic chilly bin).

Layer after layer after layer of Al foil with an occasional separator sheet of plastic bag will probably work.

Or a large-as-you-can-manage block of polystyrene.

Foil may be better.

Meds can be in a wrapping layer near the surface but deep enough to be cooler than ambient.

This can be tested in advance by using an outdoor thermometer probe and wrapping ice and watching temperature. Ice with max salt dissolved freezes at a substantially lower temperature.

Are you sure it needs refrigeration?

As a type-1 diabetic, I've travelled on many flights from the UK, including to the USA and Australia, and I've always kept my insulin just straight in hand luggage. My insulin is fine to be stored at up to about 30°C for about 4 weeks, despite what it may say about refrigeration in the instructions.

Please note I've no experience of insulin for dogs, and there may be some difference, although I'd be surprised. But I'd definitely recommend looking into whether this is a problem you actually need to solve.