It is possible to import txt files into PDF forms:  http://help.adobe.com/en_US/Acrobat/8.0/Professional/help.html?content=WS58a04a8...

Maybe you can write data to the txt file, shell to Adobe and import.  Adobe may also be a command line ability to open Adobe and do the import at the same time, have not checked that out.....

Oops, I just reread and saw that you are already manually importing.....sorry about repeating that.  

So, on to an automated process ......
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The registered version of PDFill does support command lines and/or batch files.  http://www.pdfill.com/pdf_form_filler.html.  I think I paid about $20 some time ago.  Does data import AND export as well as being a PDF editor, you can make your own forms.

Example to import text file:
C:\Program Files\PlotSoft\PDFill\PDFill.exe" IMPORT TXT SesameExport.txt EmptyForm.pdf FinalForm.pdf

No need to open any outside GUI.

Hi Bob
PDFill with its command line works great. I make the appropriate data text file to merge with PDF form elements and process is seamlessly.  Initially I struggled because the text datafile to be merged is expected in different format by PDFill as opposed to Adobe Acrobat.

Adobe Acrobat expected following format:

FieldName1 <tab> FieldName2 <tab>FieldName3<tab>......
FieldValue1 <tab> FieldValue2  <tab>FieldValue3<tab>......

While PDFill expected

FieldNames  <tab>   FieldVaules
FieldName1  <tab>   FieldValue1
FieldName2  <tab>   FieldValue2
FieldName3  <tab>   FieldValue3
FieldName4  <tab>   FieldValue4

Once I figured that out, it was a piece of cake with sBasic.

The resourcefulness of this board and hidden power of Sesame never fails to amaze me!!  Whenever I was confronted with a problem, someone invariably came up with a solution. Thanks Bob.

Hi Bob,
Automatic (One Button Press) mailmerge of pdf forms with sesame data with PDFill commandline has been implemented and works just fine. Thanks Bob