I have an invoice approval flow that has 2 stages of approvals. If the invoice is fully approved then using an html template an "approval" cover sheet is generated using properties from the item. The approval cover sheet is then merged with the original invoice and the combined pdf is saved to replace the original file uploaded and the approval cover sheet pdf is deleted.
This flow has been working without a hitch for about a year and a half now but recently the flows are failing due to an error in the Merge Pdf action. The error details show that "the input file appears to be corrupted and cannot be processed".
The flow correctly generates the approval pdf, which can be opened and viewed with no issues, and the original file can also still be opened and viewed with no issues. However, when I try to manually insert the approval pdf into the original file I am getting an error "An incorrect structure was found in the PDF file". It will continue to add the file (after acknowledging the issue) but it won't let me save it as it says its read only or open in another application.
I believe that somehow, the flow that used to work, is now corrupting the newly created approval pdf and thus making it unable to properly merge with the original file. What on earth could have changed (I've made no edits to the flow nor any connectors) that would now cause my previously working flow to cease working?
Happy to include screenshots of the flow, but as I've said, this flow was working just 1 week ago with no errors and no changes since then made to the flow.

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