For any sandwich made ahead of time it's best to wrap them tightly in plastic wrap, store them in the refrigerator until you're ready to go, then pack them in a cooler when you hit the road.
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Solid food items (not liquids or gels) can be transported in either your carry-on or checked bags. Liquid or gel food items larger than 3.4 oz are not allowed in carry-on bags and should be placed in your checked bags if possible.
You are allowed to bring a quart-sized bag of liquids, aerosols, gels, creams and pastes through the checkpoint. These are limited to 3.4 ounces (100 milliliters) or less per item. This is also known as the 3-1-1 liquids rule.
The key is to choose fillings that keep well for a handful of hours without refrigeration: cheese, cured meats (think prosciutto), hummus, grilled vegetables, and greens. To prevent soggy bread, stay away from juicy fillings like sliced tomatoes and choose a thick bread like ciabatta, focaccia, or a baguette.
Keep the food at 40 degrees F or colder.Pack your cooler with several inches of ice or use frozen gel-packs, frozen juice boxes or frozen water bottles. Block ice keeps longer than ice cubes. Use clean, empty milk or water jugs to pre-freeze blocks of ice.
You'll want to use at least two cold sources in an insulated bag to keep perishable foods in your lunch safe; ice or gel packs in your insulated bag or box work best. Perishable foods, such as cold cut sandwiches and yogurt, can be left out at room temperature for no more than 2 hours before they become unsafe to eat.