A process for forming a high loft, nonwoven web is disclosed. The process includes introducing a single molten polymer to a die having a plurality of nozzles. Emitting the molten polymer through the nozzles to form a plurality of filaments. Using air streams to facilitate movement and drawing of the filaments. Directing the filaments, which are transformed into fibers, towards a pair of heated moving surfaces. The pair of heated moving surfaces forming a convergent passage having an entry and an exit. Depositing the fibers into the entry of the convergent passage and routing the fibers between the pair of heated moving surfaces in a machine direction to form a high loft, non-woven web. The web having a fiber size distribution of from 0 μm to about 15 μm with at least about 25% of the fibers being above 4 μm.