Fractionated stillage separation and feed products

A method for separating components in a process stream, the method comprising:

• receiving a process stream having a mixture of components of one or more liquids and one or more solids;
• adding a non-condensable media to the mixture to change a density of each of the components, wherein the non-condensable media is selected from the group consisting of air, carbon dioxide, nitrogen, oxygen, and combinations thereof;
• separating the one or more liquids and the one or more solids of the process stream using an apparatus selected from the following:
• a sedicanter centrifuge, a decanter centrifuge, a disk stack centrifuge, and combinations thereof, to provide a separated solids stream and a separated liquids stream;
• separating the separated liquids stream with a first separation device to provide a light emulsion phase and a heavy phase with suspended solids;
• separating the heavy phase with suspended solids with a second separation device to provide a clarified heavy phase and a light phase concentrate, wherein the clarified heavy phase comprises 1% to 30% fat and 0.7% to 70% available oil;
• reducing viscosity of the heavy phase with suspended solids by adding a chemical to the heavy phase with suspended solids;
• and
• separating the light emulsion phase with a mechanical separation device to produce oil, heavy phase solids, and heavy phase liquids.