diff --git a/app/Helpers/merge_pdf_helper.php b/app/Helpers/merge_pdf_helper.php
index 2ae442ed..4498b9f8 100644
--- a/app/Helpers/merge_pdf_helper.php
+++ b/app/Helpers/merge_pdf_helper.php
@@ -122,6 +122,10 @@ if (! function_exists('merge_ticket_pdfs')) {
         if (! is_dir($tempDir)) {
             @mkdir($tempDir, 0775, true);
         }
+        $mpdfCacheDir = $tempDir . DIRECTORY_SEPARATOR . 'mpdf';
+        if (! is_dir($mpdfCacheDir)) {
+            @mkdir($mpdfCacheDir, 0775, true);
+        }
 
         $mergedName = 'merged_' . $ticket_master_id . '_' . time() . '_' . bin2hex(random_bytes(5)) . '.pdf';
         $mergedPath = $uploadDir . $mergedName;
@@ -271,15 +275,13 @@ if (! function_exists('merge_ticket_pdf_add_image_page')) {
     function merge_ticket_pdf_add_image_page(Mpdf $mpdf, string $imagePath): bool
     {
         $imageInfo = @getimagesize($imagePath);
-        if (empty($imageInfo[0]) || empty($imageInfo[1])) {
-            log_message('error', "merge_ticket_pdfs | invalid image | {$imagePath}");
-            return false;
-        }
+        $ext       = strtolower(pathinfo($imagePath, PATHINFO_EXTENSION));
+        $imageType = $ext === 'png' || ((int) ($imageInfo[2] ?? 0) === IMAGETYPE_PNG) ? 'png' : 'jpg';
 
-        $imageWidthPx  = (int) $imageInfo[0];
-        $imageHeightPx = (int) $imageInfo[1];
-        $imageType     = ((int) ($imageInfo[2] ?? 0) === IMAGETYPE_PNG) ? 'png' : 'jpg';
-        $isLandscape   = $imageWidthPx > $imageHeightPx;
+        $imageWidthPx  = (int) ($imageInfo[0] ?? 0);
+        $imageHeightPx = (int) ($imageInfo[1] ?? 0);
+        $hasSize       = $imageWidthPx > 0 && $imageHeightPx > 0;
+        $isLandscape   = $hasSize && $imageWidthPx > $imageHeightPx;
 
         $pageWidth  = $isLandscape ? 297 : 210;
         $pageHeight = $isLandscape ? 210 : 297;
@@ -287,11 +289,21 @@ if (! function_exists('merge_ticket_pdf_add_image_page')) {
 
         $availableWidth  = $pageWidth - ($margin * 2);
         $availableHeight = $pageHeight - ($margin * 2);
-        $scale           = min($availableWidth / $imageWidthPx, $availableHeight / $imageHeightPx);
-        $drawWidth       = $imageWidthPx * $scale;
-        $drawHeight      = $imageHeightPx * $scale;
-        $x               = ($pageWidth - $drawWidth) / 2;
-        $y               = ($pageHeight - $drawHeight) / 2;
+        if ($hasSize) {
+            $scale      = min($availableWidth / $imageWidthPx, $availableHeight / $imageHeightPx);
+            $drawWidth  = $imageWidthPx * $scale;
+            $drawHeight = $imageHeightPx * $scale;
+            $x          = ($pageWidth - $drawWidth) / 2;
+            $y          = ($pageHeight - $drawHeight) / 2;
+        } else {
+            // Some PNGs fail getimagesize(), but mPDF can still render them.
+            // Use a portrait A4 fallback and let mPDF calculate image height.
+            log_message('error', "merge_ticket_pdfs | image size unavailable, using fallback page | {$imagePath}");
+            $drawWidth  = $availableWidth;
+            $drawHeight = 0;
+            $x          = $margin;
+            $y          = $margin;
+        }
 
         $mpdf->AddPageByArray([
             'orientation'   => $isLandscape ? 'L' : 'P',