The HT-process for the expansion of cut tobacco is a well established process in the tobacco industry. The expansion is achieved by the steaming of tobacco within the HT-tunnel, which rapidly increases tobacco temperature close to the boiling point of water. Various tests under different conditions have been carried out at the Koerber AG pilot plant in order to further improve filling power of cut rag, expanded stems and cigar filler. Depending on the type of tobacco, significant improvements concerning efficiency and filling power were obtained. For example, filling power of cigar filler could be increased up to 25%. The HT-process was also used to recover cut tobacco out of winnovers separated by the maker. It was found that these winnovers contained about 30 to 40% of cut tobacco that can be returned to normal production.