One question, Can the users in JHB not use Metastorm, so there wouldn't be a need to print and send back again.
But that's a different topic.
How about using a report. Build the report to look like the form and then place a button on the form to open a report and pass in the folderid as filter paramater for your business object. This can then easily be printed, exported and save as PDF.
Additionally you could use word templates and replace placeholder with Metastorm BPM data in a server side script. You can save word files as PDF. All programatically with a bit of C# code.
This can all happen of a button click and a popup shows the final result ready to print or send via email.