I remember visiting Bob's place and seeing all the solomon disks in his living room. He also made the reactors in his garage! Nice to see you again, James!
I would still use a minimum of 2, imo, unless you were shipping within CA. If you were shipping to another state back east, with temps in the low 40's, 2 would be preferable.
I dont know about a formula, but with that much water, I would use at least 2-3 heat packs. I would also use a large igloo cooler. Way worth it in the long run and is vrtually indestructible. Are you shipping the black tang?
I'd prefer to deep fry him myself :D Nah, he should be fine. That's why you use a barbless hook. It will prevent the damage caused by a barbed one and should slip out easily. If he doesn't go for the hook at first, you may want to starve the tank for a couple days. Make sure you keep an eye...
Use the smallest hook you can find and cut off the barb, bait it with shrimp, and voila! I am dead serious about this. I use this method to catch all my fish. Do it and you will be amazed at the effectiveness of it.