This cannot be done only by using a variable name like "order.increment_id" in the email template. You have to send the tracking data to the email template processor to achieve this with an example in 4 steps.
Step1>> Add Module configuration In app/etc/modules/Eglobe_Sales.xml
<?xml version="1.0"?>
<config>
<modules>
<Eglobe_Sales>
<active>true</active>
<codePool>local</codePool>
</Eglobe_Sales>
</modules>
</config>
Step2>> Add config.xml(app/code/local/Eglobe/Sales/etc/config.xml)
<?xml version="1.0"?>
<config>
<modules>
<Eglobe_Sales>
<version>0.1.0</version>
</Eglobe_Sales>
</modules>
<global>
<models>
<sales>
<rewrite>
<order_shipment>Eglobe_Sales_Model_Order_Shipment</order_shipment>
</rewrite>
</sales>
</models>
</global>
</config>
Step3>> Override Mage_Sales_Model_Order_Shipment::sendEmail()
<?php
class Eglobe_Sales_Model_Order_Shipment extends Mage_Sales_Model_Order_Shipment {
/**
* Send email with shipment data
*
* @param boolean $notifyCustomer
* @param string $comment
* @return Mage_Sales_Model_Order_Shipment
*/
public function sendEmail($notifyCustomer = true, $comment = '')
{
$order = $this->getOrder();
$storeId = $order->getStore()->getId();
if (!Mage::helper('sales')->canSendNewShipmentEmail($storeId)) {
return $this;
}
// Get the destination email addresses to send copies to
$copyTo = $this->_getEmails(self::XML_PATH_EMAIL_COPY_TO);
$copyMethod = Mage::getStoreConfig(self::XML_PATH_EMAIL_COPY_METHOD, $storeId);
// Check if at least one recepient is found
if (!$notifyCustomer && !$copyTo) {
return $this;
}
// Start store emulation process
$appEmulation = Mage::getSingleton('core/app_emulation');
$initialEnvironmentInfo = $appEmulation->startEnvironmentEmulation($storeId);
try {
// Retrieve specified view block from appropriate design package (depends on emulated store)
$paymentBlock = Mage::helper('payment')->getInfoBlock($order->getPayment())
->setIsSecureMode(true);
$paymentBlock->getMethod()->setStore($storeId);
$paymentBlockHtml = $paymentBlock->toHtml();
} catch (Exception $exception) {
// Stop store emulation process
$appEmulation->stopEnvironmentEmulation($initialEnvironmentInfo);
throw $exception;
}
// Stop store emulation process
$appEmulation->stopEnvironmentEmulation($initialEnvironmentInfo);
// Retrieve corresponding email template id and customer name
if ($order->getCustomerIsGuest()) {
$templateId = Mage::getStoreConfig(self::XML_PATH_EMAIL_GUEST_TEMPLATE, $storeId);
$customerName = $order->getBillingAddress()->getName();
} else {
$templateId = Mage::getStoreConfig(self::XML_PATH_EMAIL_TEMPLATE, $storeId);
$customerName = $order->getCustomerName();
}
$mailer = Mage::getModel('core/email_template_mailer');
if ($notifyCustomer) {
$emailInfo = Mage::getModel('core/email_info');
$emailInfo->addTo($order->getCustomerEmail(), $customerName);
if ($copyTo && $copyMethod == 'bcc') {
// Add bcc to customer email
foreach ($copyTo as $email) {
$emailInfo->addBcc($email);
}
}
$mailer->addEmailInfo($emailInfo);
}
// Email copies are sent as separated emails if their copy method is 'copy' or a customer should not be notified
if ($copyTo && ($copyMethod == 'copy' || !$notifyCustomer)) {
foreach ($copyTo as $email) {
$emailInfo = Mage::getModel('core/email_info');
$emailInfo->addTo($email);
$mailer->addEmailInfo($emailInfo);
}
}
// Set all required params and send emails
$mailer->setSender(Mage::getStoreConfig(self::XML_PATH_EMAIL_IDENTITY, $storeId));
$mailer->setStoreId($storeId);
$mailer->setTemplateId($templateId);
$mailer->setTemplateParams(array(
'order' => $order,
'shipment' => $this,
'comment' => $comment,
'billing' => $order->getBillingAddress(),
'payment_html' => $paymentBlockHtml,
//setting the `track number here, A shihpment can have more than one track numbers so seperating by comma`
'tracks' => new Varien_Object(array('tracking_number' => implode(',', $this->getTrackingNumbers())))
)
);
$mailer->send();
return $this;
}
//Creating track number array
public function getTrackingNumbers()
{
$tracks = $this->getAllTracks();
$trackingNumbers = array();
if (count($tracks)) {
foreach ($tracks as $track) {
$trackingNumbers[] = $track->getNumber();
}
}
return $trackingNumbers;
}
}
Step4>> Modify your shipment email tempate subject by adding {{var tracks.track_number}}