In sub-Saharan Africa (SSA), many crops are contaminated by Aspergillus section Flavi fungi with highly toxic, carcinogenic aflatoxins. This contamination has severe negative impacts on health, trade, income, and development sectors, hindering progress toward various objectives of most Sustainable Development Goals (SDGs), including SDG 2 – Zero Hunger and SDG 3 – Good Health and Wellbeing. Farmers, industries, and governments need sound aflatoxin management strategies to effectively limit aflatoxin contamination throughout the crop value chain. One effective technology is biocontrol using native atoxigenic isolates of A. flavus coated on a carrier that is applied on growing crops. Atoxigenic A. flavus competitively displaces aflatoxin producers in the field, and this form of bioprotection results in reduced aflatoxin in crops. Over 15 years ago, field tests in Nigeria using a manually manufactured biocontrol product showed promising results. However, it became evident that scaling up the manufacturing process was essential to make this bioprotectant widely accessible to millions of farmers and achieve tangible impact in the context of sustainable food systems. The objective of this paper is to document the evolution of biocontrol manufacturing from small-scale, lab-based production to industrial manufacturing at different scales. The improvements in product formulation, and manufacturing processes and design are highlighted to better address “fit-to-scale” product demand in different countries. Industrializing the manufacturing process coupled with incentivization, commercialization strategies, and effective partnerships has allowed the manufacturing of thousands of tons of biocontrol products. This has enabled production of over a million tons of aflatoxin-safe maize, groundnut, and sorghum, contributing to enhanced food safety and security in several countries in SSA. The key lesson learnt is that for any input-based technology to mitigate aflatoxin (or any food safety issue), their large-scale manufacturing and commercialization is crucial for achieving tangible results. Only widespread adoption of any technology can address the great challenge posed by aflatoxins, a critical step toward meeting several SDGs. The urgency to combat aflatoxin contamination is increasing as its impacts are intensifying in several regions across the globe.

https://doi.org/10.3389/fsufs.2024.1509384

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Alejandro Ortega-Beltranhttps://orcid.org/0000-0003-3747-8094

Ranajit Bandyopadhyayhttps://orcid.org/0000-0003-2422-4298

https://doi.org/10.3389/fsufs.2024.1509384

Plant Production and Health

Aflatoxin; Agronomy; Food Security; Maize; Plant Breeding; Plant Production

Aflatoxins; Biological Control; Food Safety; Food Security; Scaling Up

Africa; Central Africa; East Africa; Southern Africa; West Africa

Burkina Faso (Upper Volta); Democratic Republic of the Congo; Ghana; Kenya; Malawi; Mali; Mozambique; Nigeria; Rwanda; Senegal; Tanzania; The Gambia; Zambia

Southern Africa Hub; Eastern Africa Hub; Headquarters and Western Africa Hub

Frontiers in Sustainable Food Systems