A Systematic Analysis of Chunking Strategies for Reliable Question Answering

We study how document chunking choices impact the reliability of Retrieval-Augmented Generation (RAG) systems in industry. While practice often relies on heuristics, our end-to-end evaluation on Natural Questions systematically varies chunking method (token, sentence, semantic, code), chunk size, overlap, and context length. We use a standard industrial setup: SPLADE retrieval and a Mistral-8B generator. We derive actionable lessons for cost-efficient deployment: (i) overlap provides no measurable benefit and increases indexing cost; (ii) sentence chunking is the most cost-effective method, matching semantic chunking up to ~5k tokens; (iii) a "context cliff" reduces quality beyond ~2.5k tokens; and (iv) optimal context depends on the goal (semantic quality peaks at small contexts; exact match at larger ones).