I want to talk about an achievement and say that sometimes costs are reduced by 20%, sometimes by 50%.
I created a solution to reduce costs by up to 50% less.
How should I phrase this?
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In your question you correctly use the phrase
costs reduced by 20%, sometimes by 50%
You don't need the word "less" and the word "reduce". You don't say "costs reduced by 20% less"
And you don't need the word "less" in your original phrase:
I created a solution to reduce costs by up to 50%.
There are other ways to phrase this, some of which have already been given in comments