The present disclosure provides a process including providing a polyolefin aqueous dispersion having (50) to (90) wt% solids content of dispersion, the polyolefin aqueous dispersion containing solid particles containing a polyolefin including an ethylene-based polymer having a melting temperature from greater than (115)°Cto (140)°C, polyolefin wax, acrylic dispersant; and an aqueous phase including excess acrylic dispersant; adding diluting water to form a diluted polyolefin aqueous dispersion having (5) to less than (50) wt% solids content; collecting the solid particles; washing the solid particles with a washing agent to remove the excess acrylic dispersant; and removing the washing agent to form a powder having a mean volume average particle size from (10) to (300) μιη, a sphericity from (0.92) to (1.0), a particle size distribution from (1) to less than (2), a particle density from (98) % to (100) %, and a flow rate in a large funnel from (1) to (5) seconds.