SURGE: SuperBatch Unified Resource-efficient GPU Encoding for Heterogeneous Partitioned Data

We present SURGE, a streaming GPU encoding system deployed in production to generate embeddings for over 800 million texts across 40,000 logical partitions. Production embedding pipelines face a tension between logical data partitioning and efficient GPU utilization: processing each partition independently incurs $P$ inter-process communication (IPC) calls whose overhead limits throughput for compute-light models. Our contributions are analytical: (i) a cost model (Theorem 1) predicting throughput within 2% across three encoders spanning a 15$\times$ parameter range; (ii) a memory-safety bound (Lemma 3) enabling a streaming two-threshold policy with peak memory $O(B_{\min} + n_{\max})$ rather than $O(N)$; and (iii) a $\phi$/CV decision framework characterizing when the pattern applies beyond our workload. The naive fix of batching at fixed size requires $O(N)$ peak memory (32.7 GB at 10M texts; infeasible beyond ~60M on 192 GB nodes), produces no output until all encoding completes, and offers no fault tolerance. SURGE achieves the same throughput with $O(B_{\min} + n_{\max})$ bounded memory (2.6 GB), 68$\times$ faster time-to-first-output, and crash recovery at SuperBatch granularity. On 10M texts with 4 NVIDIA L4 GPUs, SURGE delivers 26,413 texts/s -- matching fixed-batch throughput while using 12.6$\times$ less memory. We validate on bge-base (109M, $d$=768, error 1.3%) and across log-normal $\sigma$ in {1.0, 1.72, 2.5} (speedup invariant within $\pm$3%), and compare against a partition-batched baseline (PB-PBP-LB), against which SURGE retains a 7% throughput edge and 2.5$\times$ faster TTFO. Complementary engineering -- zero-copy Arrow serialization (22-25$\times$ speedup) and async I/O pipelining (up to 93% benefit) -- realizes the design but is not the contribution.