Order Status Email use .tpl - URGENT

Our cart work flow has several status in the workflow

incomplete → processed → being packed → dispatched

dispatch has the tracking information added via shipment method, its merged via a php scripts from XML barcode scanners

I'm trying to get the cart to send email for dispatched status with the tracking number included,

(So they phone the courier company and not the client)

I've added the new carrier as per instructions and seems to be working correctly

But I can't get emails to send? Print packaging slip won't pull the tracking id number in “Order View”

But if I access it via the shipments menu and select print packaging slip it does pull the tracking id and the carrier correctly

Cash Offered for anyone that can figure this one?

Just need help from someone who has sent the emails correctly for shipments custom carrier (NOT UPS or USPS)

Want to use .tpl some thing like this, but this won't execute via the header status


Dear {$order_info.s_firstname} {$order_info.s_lastname},

Your order #{$order_info.order_id} has been shipped from our warehouse and should be with you soon.

Your order has been sent with {$shipment.carrier} and the tracking number is {if $shipment.tracking_number} ({$shipment.tracking_number}){/if}

Please ensure someone is available to sign for this parcel.

Thank you for shopping with us.