You aren't going to be able to create a PSD w/o opening Photoshop. Even when you use something like Adobe Bridge to batch process files from any Adobe app it still uses the appropriate app to open a supported file and perform actions on it.
I have seen apps that allow you to output PDFs from user defined text and variable images (PageFlex comes to mind)...but even then, saving Adobe-compatible files aren't simple tasks to turn off and on (like when you make a text file). There's a lot of data to manage even with PDFs and I'd suspect even more when you look at a PSD file.
Unless you can find an open-source app that somehow allows you mess with its coding so that you can bypass opening it 100% to output a somewhat compatible PSD/PDF file, I don't think you're going to be able to automate much w/o lots of work and some potentially expensive software solutions.
Long answer short, I think you'll have to use Photoshop at some point in your solution. On the upside, you could make a recording of actions in PS so that individual files can be output to whatever format you like...and those I'm sure can be scripted into complicated solutions.