I have reduced my xsl to a minimum so that I can generated data to write an xml. I can't find why my two "headerline"s are not appearing. (I have reduced this example to as small as I can). I have included the files.
<?xml version="1.0"?>
<xsl:stylesheet version="1.0" xmlns:xsl="http://www.w3.org/1999/XSL/Transform"; 
                              xmlns:fo="http://www.w3.org/1999/XSL/Format";>
                              
<xsl:template match="print-compliance">
  <xsl:processing-instruction name="cocoon-format">type="text/xslfo"</xsl:processing-instruction>
  <fo:root xmlns:fo="http://www.w3.org/1999/XSL/Format";>
    <fo:layout-master-set>
      <fo:simple-page-master master-name="compliance-form"
         margin-top="50pt"
         margin-bottom="50pt"
         margin-left="15pt"
         margin-right="20pt"
         page-height="8.5in"   
         page-width="11in">
        <fo:region-body margin-bottom="1pt"/>
      </fo:simple-page-master>
    </fo:layout-master-set>
    <fo:page-sequence master-reference="compliance-form">
      <fo:flow flow-name="xsl-region-body">
        <xsl:apply-templates select="header" />
      </fo:flow>
    </fo:page-sequence>
  </fo:root>
</xsl:template>

<xsl:template match="header">
  <fo:table table-layout="fixed" border-collapse="collapse" space-before="0pt" border-style="none">
    <xsl:variable name="product_list" select="product_list" />
    <xsl:variable name="title_bg_color" select="title_bg_color" />
    <xsl:variable name="color" select="color" />
    <xsl:variable name="linespace" select="linespace" />
    <xsl:variable name="fullwidth" select="fullwidth" />
    <xsl:variable name="fontsize" select="fontsize" />
    <xsl:variable name="fontweight" select="fontweight" />
    <xsl:variable name="border" select="border" />
    <fo:table-column column-width="{$fullwidth}"/>
    <fo:table-body >
    	<fo:table-row>
        <fo:table-cell background-color="{$title_bg_color}" >
          <fo:block text-align="center" wrap-option="no-wrap" font-size="{$fontsize}" line-height="{$linespace}"
                        font-weight="{$fontweight}" color="{$color}" border="{$border}">
            <xsl:value-of select="report_name"/>
          </fo:block>
        </fo:table-cell>
      </fo:table-row>
    </fo:table-body>
  </fo:table>
  <xsl:for-each select="headerline">
  	<fo:table table-layout="fixed" border-collapse="collapse" space-before="0pt">
      <xsl:variable name="border" select="border" />
      <xsl:variable name="fontweight" select="fontweight" />
      <xsl:variable name="linespace" select="linespace" />
      <xsl:variable name="wrap" select="wrap" />
    	<xsl:for-each select="colsize">
				<xsl:variable name="width" select="value" />
				<fo:table-column column-width="{$width}"/>
    	</xsl:for-each>
    	<fo:table-body>
      	<fo:table-row line-height="{$linespace}">
      		<xsl:for-each select="hdr_item">
            <fo:table-cell wrap-option="{$wrap}">
            	<xsl:variable name="align" select="align" />
            	<xsl:variable name="color" select="color" />
            	<xsl:variable name="fontsize" select="fontsize" />
            	<xsl:variable name="bg_color" select="bg_color" />
            	<xsl:variable name="color" select="color" />
              <fo:block text-align="{$align}" font-size="{$fontsize}"  border="{$border}"
                    font-weight="{$fontweight}" color="{$color}" background-color='{$bg_color}'>
                <xsl:value-of select="value"/>
              </fo:block>
            </fo:table-cell>
          </xsl:for-each>
        </fo:table-row>
      </fo:table-body>
  	</fo:table>
 	</xsl:for-each>
</xsl:template>

</xsl:stylesheet>
<?xml version="1.0" encoding="utf-8"?>
<print-compliance>
	<header>
		<bg_color>rgb(255,190,160)</bg_color>
		<title_bg_color>darkgray</title_bg_color>
		<fontweight>bold</fontweight>		
		<color>maroon</color>
		<report_name>TITLE</report_name>
		<fullwidth>400pt</fullwidth>
		<fontsize>10pt</fontsize>
		<linespace>15pt</linespace>
		<border>none</border>
		<headerline>
			<linespace>10pt</linespace>
			<fontweight>bold</fontweight>
			<border>solid 1pt</border>
			<wrap>no-wrap</wrap>
			<colsize><value>300pt</value></colsize>
			<colsize><value>50pt</value></colsize>
			<colsize><value>50pt</value></colsize>
			<hdr_itm>
				<value>COMMODITY  </value>
				<bg_color>darkgray</bg_color>
				<color>black</color>
				<fontsize>8pt</fontsize>
				<align>end</align>
			</hdr_itm>
			<hdr_itm>
				<value>Subtitle 1</value>
				<bg_color>rgb(255,190,160)</bg_color>
				<color>black</color>
				<fontsize>6pt</fontsize>
				<align>center</align>
			</hdr_itm>
			<hdr_itm>
				<value>Subtitle 1</value>
				<bg_color>darkgray</bg_color>
				<color>black</color>
				<fontsize>6pt</fontsize>
				<align>center</align>
			</hdr_itm>
		</headerline>
		<headerline>
			<linespace>8pt</linespace>
			<fontweight>bold</fontweight>
			<wrap>no-wrap</wrap>
			<colsize><value>120pt</value></colsize>
			<colsize><value>60pt</value></colsize>
			<colsize><value>60pt</value></colsize>
			<colsize><value>30pt</value></colsize>
			<colsize><value>30pt</value></colsize>
			<colsize><value>50pt</value></colsize>
			<colsize><value>50pt</value></colsize>
			<hdr_itm>
				<value>LOCATION</value>
				<align>start</align>
				<fontsize>8pt</fontsize>
				<color>black</color>
				<bg_color>rgb(255,190,160)</bg_color>
				<border>solid .5pt</border>
			</hdr_itm>
			<hdr_itm>
				<value>RESPONSIBILITY</value>
				<fontsize>8pt</fontsize>
				<align>start</align>
				<color>black</color>
				<bg_color>rgb(255,190,160)</bg_color>
				<border>solid .5pt</border>
			</hdr_itm>
			<hdr_itm>
				<value>VICE PRESIDENT</value>
				<fontsize>8pt</fontsize>
				<align>start</align>
				<color>black</color>
				<bg_color>rgb(255,190,160)</bg_color>
				<border>solid .5pt</border>
			</hdr_itm>
			<hdr_itm>
				<value>LOG / FIN CO.</value>
				<fontsize>8pt</fontsize>
				<color>black</color>
				<align>center</align>
				<bg_color>rgb(255,190,160)</bg_color>
				<border>solid .5pt</border>
			</hdr_itm>
			<hdr_itm>
				<value>DIM.</value>
				<fontsize>8pt</fontsize>
				<color>black</color>
				<bg_color>rgb(255,190,160)</bg_color>
				<border>solid .5pt</border>
				<align>center</align>
			</hdr_itm>		
			<hdr_itm>
				<value>COMPANY 1</value>
				<color>black</color>
				<bg_color>rgb(255,190,160)</bg_color>
				<fontsize>8pt</fontsize>
				<border>solid 1pt</border>
				<align>center</align>
			</hdr_itm>
			<hdr_itm>
				<value>COMPANY 2</value>
				<fontsize>8pt</fontsize>
				<bg_color>darkgray</bg_color>
				<border>solid 1pt</border>
				<align>center</align>
			</hdr_itm>
		</headerline>
	</header>
</print-compliance>
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