I was able to resolve this issue after a lot of head scratching. Although I do have a staging environment and this code ran on both development and staging, it was still failing when I pushed to production. botp's comments above gave me a great clue about marshaled objects across versions. Turns out my capistrano deploy recipe was calling "bundle install" with no flags in production. For whatever reason it had always worked. As soon as I changed to "bundle install --deployment" all was well again.
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