Aflatoxin, a harmful secondary metabolite produced by Aspergillus flavus and Aspergillus parasiticus, poses a significant risk to human health and food safety. Therefore, the development of safe and environmentally friendly techniques for controlling A. flavus and its aflatoxin production is imperative. In this study, Bacillus velezensis 906 cell-free fermentation supernatant (CFS) inhibited the germination of A. flavus spores and mycelium growth. Scanning electron microscopy and fluorescence microscopy revealed that CFS altered cell morphology and damaged the cell membrane of A. flavus leading to cell death. Fourier transform infrared spectroscopy indicated changes in the functional groups of A. flavus filaments treated with CFS. The trend in ergosterol content demonstrated that CFS effectively inhibited the normal growth of A. flavus cell membranes. The CFS exhibited remarkable efficacy in degrading aflatoxin B1 (AFB1), achieving a degradation rate of up to 60% after 48 h of interaction. The addition of 0.2 mg/mL Cu2+ or Fe3+ metal ions to CFS significantly increased the degradation rate of AFB1 up to 90%. Furthermore, the analysis indicated that the active components responsible for AFB1 degradation might be heat-resistance and exhibit resistance to protease K. These findings underscore the potential of CFS as a green, safe, and economically viable strategy for controlling aflatoxin production by A. flavus, offering promising prospects for mitigating mold contamination in food and feed applications.
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