diff --git a/app/Http/Controllers/ShippingController.php b/app/Http/Controllers/ShippingController.php
index d73e6fa..8911b4e 100644
--- a/app/Http/Controllers/ShippingController.php
+++ b/app/Http/Controllers/ShippingController.php
@@ -23,120 +23,30 @@ class ShippingController extends Controller
      */
     public function createShipment(Request $request, Order $order)
     {
-        Log::info('Initiating shipment creation', ['order_uuid' => $order->uuid]);
-        // Guard 1: Verify packing completed with valid dimensions
-        if (! $this->validatePackingGate($order)) {
-            Log::warning('Packing gate validation failed', [
-                'order_uuid' => $order->uuid,
-                'packing_completed_at' => $order->packing_completed_at,
-                'width' => $order->packing_width,
-                'length' => $order->packing_length,
-                'weight' => $order->packing_weight,
-            ]);
-            return response()->json([
-                'error' => 'Order not yet packed with valid dimensions',
-                'details' => [
-                    'packing_completed_at' => $order->packing_completed_at,
-                    'dimensions' => [
-                        'width' => $order->packing_width,
-                        'length' => $order->packing_length,
-                        'weight' => $order->packing_weight,
-                    ],
-                ],
-            ], 400);
-        }
-
-        // Guard 2: Verify payment and approval rules
-        if (! $this->validatePaymentAndApprovalGate($order)) {
-            $message = $order->is_custom_order ? 
-                'Custom order requires proof approved and balance paid' :
-                'Standard order must be fully paid';
-            Log::warning('Payment/approval gate validation failed', [
-                'order_uuid' => $order->uuid,
-                'is_custom_order' => $order->is_custom_order,
-                'payment_status' => $order->payment_status,
-            ]);
-            return response()->json([
-                'error' => $message,
-                'payment_status' => $order->payment_status,
-            ], 403);
-        }Log::warning('Order status gate validation failed', [
-                'order_uuid' => $order->uuid,
-                'expected_status' => 'ready_to_ship',
-                'current_status' => $order->status,
-            ]);
-            
-
-        // Guard 3: Check order status is Ready to Ship
-        if ($order->status !== 'ready_to_ship') {
-            return response()->json([
-                'error' => 'Order must be in Ready to Ship state',
-                'current_status' => $order->status,
-            ], 409);
-        }
-
-        // Guard 4: Idempotency - if already shipped, return existing shipment
-        if ($order->courier_waybill_id) {
-            Log::info('Shipment already exists, returning existing', ['order_uuid' => $order->uuid]);
-
-            return response()->json([
-                'success' => true,
-                'message' => 'Shipment already created',
-                'shipment' => [
-                    'waybill_id' => $order->courier_waybill_id,
-                    'tracking_number' => $order->courier_tracking_number,
-                ],
-            ]);
-        }
-
         try {
-            // Call courier API
-            $shipmentData = $this->courierService->createShipment(
-                $order->id,
-                $order->packing_width,
-                $order->packing_length,
-                $order->packing_weight,
-            );
+            $result = $this->courierService->createShipmentForOrder($order);
 
-            // Save shipment details
-            $order->update([
-                'courier_waybill_id' => $shipmentData['waybill_id'],
-                'courier_tracking_number' => $shipmentData['tracking_number'],
-                'courier_status' => 'awaiting_collection',
-                'status' => 'awaiting_collection',
-            ]);
-
-            Log::info('Shipment created with courier', [
-                'order_uuid' => $order->uuid,
-                'waybill_id' => $shipmentData['waybill_id'],
-                'tracking_number' => $shipmentData['tracking_number'],
-            ]);
-
-            // Fetch and store shipping documents
-            $stickerPath = $this->courierService->fetchSticker($shipmentData['shipment_id'], $order->id);
-            $waybillPath = $this->courierService->fetchWaybill($shipmentData['shipment_id'], $order->id);
-
-            // Emit event to trigger Trello update, Slack notification, document attachment
+            // Emit event to trigger Slack notification and Trello updates
             ShipmentCreated::dispatch(
                 $order,
-                $shipmentData['waybill_id'],
-                $shipmentData['tracking_number'],
-                $stickerPath,
-                $waybillPath,
+                $result['waybill_id'],
+                $result['tracking_number'],
+                $result['sticker_path'],
+                $result['waybill_path'],
             );
 
             return response()->json([
                 'success' => true,
                 'message' => 'Shipment created successfully',
                 'shipment' => [
-                    'waybill_id' => $shipmentData['waybill_id'],
-                    'tracking_number' => $shipmentData['tracking_number'],
-                    'sticker' => $stickerPath ? route('storage.file', $stickerPath) : null,
-                    'waybill' => $waybillPath ? route('storage.file', $waybillPath) : null,
+                    'waybill_id' => $result['waybill_id'],
+                    'tracking_number' => $result['tracking_number'],
+                    'sticker' => $result['sticker_path'] ? route('storage.file', $result['sticker_path']) : null,
+                    'waybill' => $result['waybill_path'] ? route('storage.file', $result['waybill_path']) : null,
                 ],
             ]);
         } catch (\Exception $e) {
-            Log::error('Failed to create shipment', [
+            Log::error('Shipment creation failed', [
                 'order_uuid' => $order->uuid,
                 'error' => $e->getMessage(),
             ]);
@@ -147,7 +57,7 @@ class ShippingController extends Controller
             return response()->json([
                 'error' => 'Failed to create shipment',
                 'message' => $e->getMessage(),
-            ], 500);
+            ], 400);
         }
     }
 
@@ -169,30 +79,4 @@ class ShippingController extends Controller
         // Re-run the shipment creation
         return $this->createShipment($request, $order);
     }
-
-    /**
-     * Validate packing gate: order must be packed with dimensions
-     */
-    private function validatePackingGate(Order $order): bool
-    {
-        return $order->packing_completed_at !== null &&
-            $order->packing_width > 0 &&
-            $order->packing_length > 0 &&
-            $order->packing_weight > 0;
-    }
-
-    /**
-     * Validate payment and approval gate
-     */
-    private function validatePaymentAndApprovalGate(Order $order): bool
-    {
-        // Standard orders: must be fully paid
-        if ($order->is_custom_order === false) {
-            return $order->payment_status === 'paid';
-        }
-
-        // Custom orders: proof must be approved and balance must be paid
-        // TODO: Add proof_approved and balance_status fields to CustomOrder model
-        return true; // Placeholder - update when custom order model is ready
-    }
 }
diff --git a/app/Listeners/CreateShipmentOnReadyToShip.php b/app/Listeners/CreateShipmentOnReadyToShip.php
index 5d2e5b1..41cbdd2 100644
--- a/app/Listeners/CreateShipmentOnReadyToShip.php
+++ b/app/Listeners/CreateShipmentOnReadyToShip.php
@@ -28,71 +28,16 @@ class CreateShipmentOnReadyToShip
             'order_uuid' => $order->uuid,
         ]);
 
-        // Validate packing
-        if (! $order->packing_completed_at || ! $order->packing_width || ! $order->packing_length || ! $order->packing_weight) {
-            Log::warning('Cannot create shipment - order not packed', [
-                'order_uuid' => $order->uuid,
-                'packing_completed_at' => $order->packing_completed_at,
-            ]);
-            return;
-        }
-
-        // Validate payment
-        if ($order->is_custom_order === false && $order->payment_status !== 'paid') {
-            Log::warning('Cannot create shipment - order not paid', [
-                'order_uuid' => $order->uuid,
-                'payment_status' => $order->payment_status,
-            ]);
-            return;
-        }
-
-        // Prevent duplicate shipments
-        if ($order->courier_waybill_id) {
-            Log::info('Shipment already exists for this order', [
-                'order_uuid' => $order->uuid,
-                'waybill_id' => $order->courier_waybill_id,
-            ]);
-            return;
-        }
-
         try {
-            Log::debug('Calling courier API to create shipment', [
-                'order_uuid' => $order->uuid,
-            ]);
-
-            // Call courier API
-            $shipmentData = $this->courierService->createShipment(
-                $order->id,
-                $order->packing_width,
-                $order->packing_length,
-                $order->packing_weight,
-            );
-
-            // Save shipment details
-            $order->update([
-                'courier_waybill_id' => $shipmentData['waybill_id'],
-                'courier_tracking_number' => $shipmentData['tracking_number'],
-                'courier_status' => 'awaiting_collection',
-                'status' => 'awaiting_collection',
-            ]);
-
-            Log::info('Shipment created successfully from webhook', [
-                'order_uuid' => $order->uuid,
-                'waybill_id' => $shipmentData['waybill_id'],
-                'tracking_number' => $shipmentData['tracking_number'],
-            ]);
-
-            // Fetch shipping documents
-            $stickerPath = $this->courierService->fetchSticker($shipmentData['shipment_id'], $order->id);
-            $waybillPath = $this->courierService->fetchWaybill($shipmentData['shipment_id'], $order->id);
+            $result = $this->courierService->createShipmentForOrder($order);
 
             // Emit event to trigger Slack/Trello updates
             ShipmentCreated::dispatch(
                 $order,
-                $shipmentData['waybill_id'],
-                $shipmentData['tracking_number'],
-                $stickerPath,
-                $waybillPath,
+                $result['waybill_id'],
+                $result['tracking_number'],
+                $result['sticker_path'],
+                $result['waybill_path'],
             );
         } catch (\Exception $e) {
             Log::error('Failed to create shipment from Ready to Ship intent', [
diff --git a/app/Services/CourierService.php b/app/Services/CourierService.php
index 3761157..4ad6ffb 100644
--- a/app/Services/CourierService.php
+++ b/app/Services/CourierService.php
@@ -2,6 +2,7 @@
 
 namespace App\Services;
 
+use App\Models\Order;
 use Illuminate\Support\Facades\Http;
 use Illuminate\Support\Facades\Log;
 use Illuminate\Support\Facades\Storage;
@@ -18,7 +19,83 @@ class CourierService
     }
 
     /**
-     * Create a shipment with Shiplogic
+     * Create shipment with full validation and database updates
+     * 
+     * @param Order $order
+     * @return array{waybill_id: string, tracking_number: string, sticker_path: ?string, waybill_path: ?string}
+     * @throws \Exception
+     */
+    public function createShipmentForOrder(Order $order): array
+    {
+        Log::info('Creating shipment for order', ['order_uuid' => $order->uuid]);
+
+        // Guard 1: Validate packing
+        if (! $this->validatePacking($order)) {
+            throw new \Exception('Order not yet packed with valid dimensions');
+        }
+
+        // Guard 2: Validate payment/approval
+        if (! $this->validatePayment($order)) {
+            throw new \Exception($order->is_custom_order ?
+                'Custom order requires proof approved and balance paid' :
+                'Standard order must be fully paid'
+            );
+        }
+
+        // Guard 3: Validate order status
+        if ($order->status !== 'ready_to_ship') {
+            throw new \Exception('Order must be in Ready to Ship state');
+        }
+
+        // Guard 4: Prevent duplicates
+        if ($order->courier_waybill_id) {
+            throw new \Exception('Shipment already exists for this order');
+        }
+
+        try {
+            // Call API to create shipment
+            $shipmentData = $this->callCreateShipmentApi(
+                $order->id,
+                $order->packing_width,
+                $order->packing_length,
+                $order->packing_weight,
+            );
+
+            // Save shipment details to database
+            $order->update([
+                'courier_waybill_id' => $shipmentData['waybill_id'],
+                'courier_tracking_number' => $shipmentData['tracking_number'],
+                'courier_status' => 'awaiting_collection',
+                'status' => 'awaiting_collection',
+            ]);
+
+            Log::info('Shipment created successfully', [
+                'order_uuid' => $order->uuid,
+                'waybill_id' => $shipmentData['waybill_id'],
+            ]);
+
+            // Fetch shipping documents
+            $stickerPath = $this->fetchSticker($shipmentData['shipment_id'], $order->id);
+            $waybillPath = $this->fetchWaybill($shipmentData['shipment_id'], $order->id);
+
+            return [
+                'waybill_id' => $shipmentData['waybill_id'],
+                'tracking_number' => $shipmentData['tracking_number'],
+                'sticker_path' => $stickerPath,
+                'waybill_path' => $waybillPath,
+            ];
+        } catch (\Exception $e) {
+            Log::error('Failed to create shipment', [
+                'order_uuid' => $order->uuid,
+                'error' => $e->getMessage(),
+            ]);
+
+            throw $e;
+        }
+    }
+
+    /**
+     * Create a shipment with Shiplogic API
      * 
      * @param string $orderId
      * @param float $width Width in cm
@@ -27,7 +104,7 @@ class CourierService
      * @return array{shipment_id: string, waybill_id: string, tracking_number: string}
      * @throws \Exception
      */
-    public function createShipment(string $orderId, float $width, float $length, float $weight): array
+    private function callCreateShipmentApi(string $orderId, float $width, float $length, float $weight): array
     {
         if (! $this->isConfigured()) {
             throw new \Exception('Courier API not configured');
@@ -69,7 +146,7 @@ class CourierService
                 'tracking_number' => $data['tracking_number'] ?? null,
             ];
         } catch (\Exception $e) {
-            Log::error('Failed to create shipment with courier', [
+            Log::error('Failed to call courier API', [
                 'order_id' => $orderId,
                 'error' => $e->getMessage(),
             ]);
@@ -78,6 +155,54 @@ class CourierService
         }
     }
 
+    /**
+     * Validate packing gate: order must be packed with dimensions
+     */
+    private function validatePacking(Order $order): bool
+    {
+        $valid = $order->packing_completed_at !== null &&
+            $order->packing_width > 0 &&
+            $order->packing_length > 0 &&
+            $order->packing_weight > 0;
+
+        if (! $valid) {
+            Log::warning('Packing validation failed', [
+                'order_uuid' => $order->uuid,
+                'packing_completed_at' => $order->packing_completed_at,
+                'width' => $order->packing_width,
+                'length' => $order->packing_length,
+                'weight' => $order->packing_weight,
+            ]);
+        }
+
+        return $valid;
+    }
+
+    /**
+     * Validate payment and approval gate
+     */
+    private function validatePayment(Order $order): bool
+    {
+        // Standard orders: must be fully paid
+        if ($order->is_custom_order === false) {
+            $valid = $order->payment_status === 'paid';
+        } else {
+            // Custom orders: proof must be approved and balance must be paid
+            // TODO: Add proof_approved and balance_status fields to CustomOrder model
+            $valid = true; // Placeholder
+        }
+
+        if (! $valid) {
+            Log::warning('Payment validation failed', [
+                'order_uuid' => $order->uuid,
+                'is_custom_order' => $order->is_custom_order,
+                'payment_status' => $order->payment_status,
+            ]);
+        }
+
+        return $valid;
+    }
+
     /**
      * Fetch shipping label/sticker PDF from Shiplogic
      */