Is there any alternative or work around to HTML to PDF convert in apex?
Please help and provide your suggestions.
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Although certainly not the only culprits to mucking up a straight-forward conversion from a VF markup to PDF using the "renderAs" tag... I would carefully review all your CSS or other style markups, as they tend to cause failures in the PDF rendering engine if not carefully-considered.
It is, shall we say, not so easy to get a good PDF rendering with a nice HTML markup as a starting point; not so easy to find "offending element" in your CSS, especially as nice eye-pleasing webpages tend to have lots of markup.
On numerous occasions, I have found it necessary to remove ALL of the CSS and add it back in piecemeal in order to arrive to the destination -- a fully-rendered PDF version of my page.
There are a number of AppExchange packages that can generate a PDF using a template- Conga, Drawloop, and Thunderhead are three well known ones. Generally these templates are built in Word or another editor though - not HTML or Visualforce.
Document generation for most of these products is "ad-hoc" - users click on a button in Salesforce to generate the document. But I know Conga has a workflow add-on that allows documents to be generated from a workflow rule in Salesforce, or via outbound message. This would possibly better suit your use case, as it could be massaged to be initiated from Apex. https://www.congasphere.com/products/workflow/C_about_workflow.htm.
I'm sure other products would have similar add-ons available as well.