I think your only option is to run 10.5 virtually. Seriously, what serious developer makes software that costs that much and can't keep it up to date with the machines to run it? Just got me wondering, that's all.
The OP did mention that the patch would cost £24K. This is quite common practice with software houses where costs of updates is dependent on the after-sales support options chosen.
Anyway back to topic, how is the OP's current MBP on its last legs? Would a complete reinstall of OSX or any hardware upgrade (eg. RAM/HDD) help? If the current MBP could be made to last the next 12 months until the workflow migration, it might save a bit of a headache.
IMO there are too many differences between 10.6 and 10.5 to try and troubleshoot the problem without knowing the nitty gritty of the workflow app.
The downgrade in Java wouldn't have worked because the newer version "should be" backwards compatible but the OP probably knew that anyway.