Abstract: A process and apparatus for improved expansion of tobacco is disclosed wherein tobacco impregnated with a volatile impregnant is treated prior to expansion, in an intermediate stage wherein a gaseous phase containing volatile impregnant vapors is removed and later recovered. The thus treated tobacco is thereafter expanded in a conventional expansion zone by contacting the tobacco with a stream of hot gases. The invention results in more efficient use of volatile impregnant and can provide less residual impregnant in expanded tobacco while not decreasing the degree of tobacco expansion.