Сделал так:
if ($order_info['shipping_address_format']) {
$format = $order_info['shipping_address_format'];
} else {
$format = '{firstname} {lastname}' . "\n" . '{company}' . "\n" . '{address_1}' . "\n" . '{address_2}' . "\n" . '{city} {postcode}' . "\n" . '{zone}' . "\n" . '{country}' . "\n" . '{custom_field_5}';
}
$find = array(
'{firstname}',
'{lastname}',
'{company}',
'{address_1}',
'{address_2}',
'{city}',
'{postcode}',
'{zone}',
'{zone_code}',
'{country}',
'{custom_field_5}'
);
$replace = array(
'firstname' => $order_info['shipping_firstname'],
'lastname' => $order_info['shipping_lastname'],
'company' => $order_info['shipping_company'],
'address_1' => $order_info['shipping_address_1'],
'address_2' => $order_info['shipping_address_2'],
'city' => $order_info['shipping_city'],
'postcode' => $order_info['shipping_postcode'],
'zone' => $order_info['shipping_zone'],
'zone_code' => $order_info['shipping_zone_code'],
'country' => $order_info['shipping_country'],
'custom_field_5' => $order_info['custom_field']
);
$data['shipping_address'] = str_replace(array("\r\n", "\r", "\n"), '<br />', preg_replace(array("/\s\s+/", "/\r\r+/", "/\n\n+/"), '<br />', trim(str_replace($find, $replace, $format))));
$this->load->model('tool/upload');
Теперь в письме выводится "Array". Уже что-то выводится!))
Как же теперь дальше распаковать этот аррэй?