I have just been recycling styrofoam inserts from all the orders I've done online, but my supply is running low. Looking around, prices seem fairly high. I just need the liners for a 7x7x6 box. 30 sets for $35 is the cheapest I can find them at so far, but I would think I can find them cheaper - not?
If you are willing to cut your own, you could buy sheet Styro at a hardware or building supply store. I have bought some at Home Depot.
Cut to size, just a bit snug, and it is just as good as if it was made for the box.
The nice thing about the boxes is that they are waterproof. I've had a very expensive discus survive when fedex tried their best to destroy a box of Wayne ng discus. The water in the bottom of the box saved the fish. I guess it depends what you are shipping.
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If you know someone who works at a hospital or a lab, check with them. A lot of lab and medical stuff comes refrigerated/frozen, and most of the time the whole package gets chucked in the trash/recycling (stryofoam box, lid, cardboard outer box, cold packs, etc.).