I can state in no uncertain terms the issue is not caused by this module. The line you are referencing calls A) a core PHP function and B) a core Zen Cart function (not altered by this module and calling mostly core PHP functions). How are those generating a 1.6G request to be stored in memory?
You can also try disabling the individual "caches" for products and categories. Should not affect the posted lines of code in anyway, but will lower the memory footprint of this module.
Corrupted Uploads are another item you can check: Make sure when transferring the files using an FTP program it uses "text" not "binary" for PHP files. Also double check any manual merged files to ensure the documents are in the correct character set (and not mixed character sets from a copy / paste). The distributed files are encoded using UTF8 (you can try converting to US-ASCII if your hosting provider has issues with UTF8 encoded PHP files).
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