For everyone and anyone interested in a method to ship chocolate during the summer months here is what I do (my shop is based out of Southern California where temps during the summer can get over 100)
Here is how I ship my chocolate truffles.
I freeze my gel-packs (from ULine, either 16 oz. or 24 oz. depending on amount of truffles and where its headed),
The first thing I do is tape the bottom of the box good, and I mean goooood. I get the middle (length) (one strip down the immediate middle, one strip on both sides overlapping the first strip), then I tape the other openings on the bottom (width) ensure all opening where air can enter or exit is sealed.
I take moisture control paper ( you can use other packaging material just make sure it is moisture control) and create a thin layer on the bottom of the box.
I then wrap the frozen gel-pac in bubble wrap only a single layer is needed. (this is important for helping with moisture control) and place it directly on top of the bottom packaging material.
I then put the box of chocolate truffles directly on top of the bubble wrapped gel-pac and continue to stuff the rest of the box with the same moisture control packaging.
To help protect the tops of the boxes of chocolate from possibly getting crushed or damaged I place one layer of bubble wrap on top of the box of chocolates and let it overlap the inside packaging. And then one single layer of moisture control packaging on top.
I close the top of the box and tape it up exactly how the bottom was taped up.
One of the key points is, you need to make sure all openings of the box are sealed good from air exiting or entering this will help with controlling the inside temperatures.
The other key point is the moisture control packaging, us chocolatiers know that chocolate and moisture are arch-enemies, the packaging helps with any moisture build up from the gel-pac.
I am sorry this seams long-winded, but this has and still works for me. Also I have a tendency to package my shipments right before I take them to the in store drop off location right before the deadline, this way it ensures they aren't sitting around at home or in a shop that may not run a/c and defintiely not in a hot van or warehouse waiting to be sorted for delivery (since sorting and travel of packages to different states happens at night).
I hope this helps a lil
